Abstract:Wrinkling and fracture are main defects in sheet metal forming of aluminum alloy sheet, which can be reduced or even eliminated by manipulating a suitable blank-holder forces (BHF). But, it is difficult to attain the optimum BHF during sheet metal forming. A new optimization algorithm integrating the finite element method (FEM) and adaptive response surface method is presented to determinate the optimal BHFs in deep drawing of aluminum rectangular box. To as-
sure convergence, the trust region modes management strategies are used to adjust the move limit of design spaces. Finally, the optimum results of rectangular box deep drawing are given. Verification experiments are performed to verify the optimal result.

Key words: aluminum alloy sheets; blank-holder force; optimization; sheet metal forming